Apparatus and method for sealing a fuel component in a fuel communication passage

ABSTRACT

A fuel component assembly having a fuel component disposed between a base and a cover, which prevent fluid communication to an exterior thereof. The fuel component defines at least one aperture, the base supports the fuel component and defines a passage in communication with the at least one aperture. The cover is located proximate the base. A securement having a projection and the receiver that engage to form a fluid tight seal. The projection is radially disposed about a longitudinal axis of the fuel component, and the receiver continuously engages the projection. The projection being disposed on one of the cover and the base, and the receiver being disposed on the other of the cover and the base. The fuel component assembly allows for a method of encapsulating a fuel component within a fuel supply. The method can be achieve by defining a passage within a base of an assembly; seating the fuel component within the passage; providing a cover that is contiguous with the base; and welding the cover to the base to form a hermetic seal. The fuel component assembly also provides a method of regulating a fuel supply. The method can be achieved by encapsulating a fuel component within a passage defined by a continuous wall of a housing; and controlling the pressure of fuel within the passage with the fuel component.

This divisional application claims the benefits of 35 U.S.C. §120 basedon U.S. application Ser. No. 09/922.696, now U.S. Pat. No. 6,619,314filed Aug. 7, 2001, entitled “Apparatus and Method for Sealing FuelComponent in a Fuel Communication Passage,” which is hereby incorporatedby reference in its entirety in this divisional application.

BACKGROUND OF THE INVENTION

The disclosed invention relates generally to regulation of fuel within afuel passage. There is a need for new and innovative approach forinstalling a fuel component such as a fuel regulator within a fuelpassage such as a fuel supply line. This invention responds to that needby sealing a fuel component within a fuel communication passage withoutan elastomeric member.

SUMMARY OF THE INVENTION

The present invention provides a fuel component assembly having a fuelcomponent disposed within a housing. The fuel component defines at leastone aperture that receives fuel. The housing preferably, has a base anda cover. The base supports the fuel component and defines a passage incommunication with the at least one aperture of the fuel component. Thecover is located proximate the base, and a securement is employed to fixthe cover to the base. The securement has a projection radicallydisposed about a longitudinal axis, and a receiver that continuouslyengages the projection. The projection is disposed on one of the coverand the base, and the receiver being disposed on the other of the coverand the base.

The present invention also provides a method of encapsulating a fuelcomponent within a fuel supply. The method is preferably achieved bydefining a passage within a base of an assembly; seating the fuelcomponent within the passage; providing a cover that is contiguous withthe base; and welding the cover to the base to form a hermetic seal.

The present invention further provides a method of regulating a fuelsupply. The method is preferably achieved by encapsulating a fuelcomponent within a passage defined by a continuous wall of a housing;and controlling the pressure of fuel within the passage with the fuelcomponent.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and constitutepart of this specification, illustrate an embodiment of the invention,and, together with the general description given above and the detaileddescription given below, serve to explain the features of the invention.

FIG. 1 illustrates a cross section of a first preferred embodiment, inwhich the fuel component is a fuel damper.

FIG. 2 illustrates a second preferred embodiment, in which the fuelcomponent is a fuel regulator.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 illustrates a fuel component assembly 10. The assembly 10includes a fuel component 20, a base 30, a cover 40 and a securement 50.The fuel component 20 defines at least one aperture 22. The fuelcomponent 20 is supported by a base 30. The base 30 defines a passage 32which is in communication with the aperture(s) 22. The assembly 10further comprises a cover 40 which is proximate to a base 30. The cover40 and the base 30 are secured to one another to create a contiguousseal that prevents communications to the fuel component 20. The seal isachieved by providing a securement 50. The securement 50, preferably,includes a projection 52 which is radially disposed about a longitudinalaxis 54. The securement 50, further comprises a receiver 56 thatcontiguously engages the projection 52. The seal may be a hermetic seal.The seal may include a weldment 58.

The fuel component 20, illustrated in preferred embodiments of FIGS. 1and 2, comprises a flange 24, an upper housing 28 a and a lower housing28 which is proximate the flange. The flange 24 supports the fuelcomponent 20 with the base 30 and cover 40.

The fuel component 20 may be a fuel pressure regulator, a damping deviceor some other device as those skilled in the art will appreciate whichregulates the pressure in a fuel supply. An example of a fuel component,the operation of which would benefit from this assembly is a pressureregulator, illustrated in U.S. Pat. Nos. 4,928,729 and 5,163,468,however the regulator disclosed in each of these patents would beconfigured to have an upper housing without a nipple. One example of afuel damper, the operation of which will benefit from this assembly,illustrated in U.S. Pat. No. 6,230,685 which are hereby incorporated intheir entirety by reference.

In the embodiment illustrated in FIG. 2, fuel component 20 furthercomprises a ring 26, which is located at an end of the lower housing 28opposite the end and is proximate the flange 24.

In the embodiments of FIGS. 1 and 2, the base 30 is disposed about alongitudinal axis 54. The base 30 has a radial wall 37 which is disposedabout the longitudinal axis 54. The radial wall 37 has a lower wall 37 aand an upper wall 37 b. The lower wall has a platform 37 c and a rise 37d. The rise. 37 d, in the embodiment of FIG. 1, is parallel to thelongitudinal axis 54. In alternative embodiments, however, non-parallelconfigurations may be employed so long as these configuration providesthe required support function that the rise provides to the base.

The lower wall 37 a in the embodiment illustrated in FIG. 2 defines aplatform 37 c and comprises an inner surface 34 which defines a chamber36. The inner surface 34 in this embodiment is configured to be disposedabout a lower chamber 28 such that aperture 22′ is in communication withchamber 36 and passage 32 b. The inner surface 34 in this embodiment, isfurther configured such that it constrains the fuel component 20 frommoving relative to the longitudinal axis 54 by supporting the fuelcomponent 20 at ring 24. Alternatively, as shown in FIG. 1, innersurface 34 can be configured to constrain fuel component 20 relative tothe longitudinal axis 54, by supporting the fuel component 20 at thelower chamber 28.

The platform 37 c is adapted to support the fuel component 20. In theembodiments shown, the platform supports the fuel component 20 at thefuel component flange 24 such that the fuel component 20 is restrainedfrom moving relative to an axis which is perpendicular to longitudinalaxis 54. The flange 24 may extend across the full distance acrossplatform 37 c, however, in the preferred embodiment such a configurationof flange 24 is not required. Alternatively, the flange 24 and the base37 can be dimensioned such that the base supports the flange to restrictmovement relative the longitudinal axis 54.

In FIGS. 1 and 2, a passage 32 is defined by the base 30 and is furtherdefined by an inner surface 34. As is illustrated in FIGS. 1 and 2, theinner surface 34 is, preferably, configured to constrain the fuelcomponent 20 from movement with respect to the longitudinal axis 54.Other embodiments may utilize other surfaces for features of componentsto restrain fuel component 20 instead of or in addition to surface 34.One example of such a configuration is where a fuel component flange isconfigured to restrain the fuel component from motion relative to bothlongitudinal and transverse axes.

In the embodiment shown in FIG. 1, inner surface 34 additionally definesa chamber 36 wherein the fuel component 20 is constrained from movementwith respect to the longitudinal axis 54. In this embodiment, chamber 36and passage 32 a are disposed in communication with one another. Passage32 a is disposed about an axis 38 which is transverse to thelongitudinal axis 54. Alternatively, passage 32 may be disposed about anaxis which is parallel to the longitudinal axis 54. For example, FIG. 2illustrates, an embodiment with a parallel axis co-axial with axis 54.

The base 30 may also define a second passage 32 b which is incommunication with the first passage 32. This second passage 32 b may bedisposed about an axis which is convergent with the longitudinal axis54. Alternatively, FIG. 2, illustrates an embodiment where the secondpassage 32 b is disposed about an axis 35 which is perpendicular to axis54.

FIG. 1 illustrates, the fuel component 20, the chamber 36, and thepassage 32 each dimensioned such that the aperture 22 is positionedbetween the transverse axis 38 and the portion of the inner surface ofpassage 32 a that meets with rise 37 d. This configurationadvantageously exposes the aperture 22 to the flow of fuel in passage 32while maintaining communication with the chamber 36. Those skilled inthe art will appreciate that placement of the aperture 22 may varydepending on the desired results and the type of fuel componentselected. In embodiments where the fuel component is a flow-through-typefuel component, and there is an inlet and outlet aperture utilized, eachaperture will be aligned with a respective passage. For example, in FIG.2, fuel component 20 includes a second aperture 22′, which is,preferably, aperture aligned with passage 32 b.

In FIGS. 1 and 2, the upper wall 37 b has a proximal end 37 e and adistal end 37 f. The proximal end 37 e is in continuity with theplatform 37 c and the distal end 37 f extends therefrom. The upper wall37 b may be, as is illustrated in the FIG. 1 and 2, parallel to thelongitudinal axis 54 though other configurations may also be used toform the cavity. As illustrated in FIG. 1 and 2, the inner surface ofradial wall 37 defines a cavity; the upper wall 37 b defining an uppercavity. In the configuration shown, the upper wall 37 b also serves asan element of securement 50.

Securement 50 as illustrated in FIGS. 1 and 2 is a continuous joint thatprevents fluid communication from the assembly. Preferably, the joint isa mechanical coupling of the cover to the base. The mechanical couplingmay include a gasket, however, the gasket should not be the primarydevice to form the fluid tight connection. The connection can be adirect connection between the cover and the base. Alternatively, theconnection between the cover and the base could include intermediatecomponents to provide an indirect connection. The intermediatecomponents of the indirect connection between the cover and the baseshould include non-elastomeric members. Preferably, the non-elastomericmembers would be rigid members fixed to the cover, the base, or both.

The securement may also provide structural support among the componentsof the assembly. As illustrated in the preferred embodiments, securement50 comprises a projection 52 and a receiver 56. The projection 52 andthe receiver 56 can be provided on either of the base or cover.Additional more than one type projections [and or receiver 56 could beused to form the securement 50, and portions of each projection 52 andreceiver 56 can be located on the cover, the base, or both so long asthe securement forms a fluid tight mechanical seal. Preferably, theprojection 52 in FIG. 1 and 2 is formed by the upper wall 37 b, and isdimensioned such that it can be fit into a receiver 57. There may beconfigurations, such as in FIG. 1 and 2, where it is advantageous totaper the projection 56. In the embodiment of FIGS. 1 and 2, thereceiver 56 has three inner surfaces 56 a, b, and c. Each of these innersurfaces engages the projection 52. The securement may alternatively beachieved by with fewer or greater than three surfaces of engagement. Thesecurement may also be achieved by laser welding a wall of the base tothe cover. The securement may further be achieved by providing a bump oneither the base or the cover which engages a groove on the other of thecover or the base.

The securement 50 illustrated in FIGS. 1 and 2 also incorporates aweldment 58. The weldment 58 may be located at the tip of the projection52 as illustrated in FIGS. 1 and 2. The placement of the weldment mayvary depending on the configuration of the securement. Where theassembly is plastic, this weldment 58 may be of the spin, ultrasonic, orsolvent type. Though FIGS. 1 and 2 demonstrate a securement configuredwith the projection 52 on the base 30, and the receiver 56 on the cover40, the opposite embodiment might be equally advantageous; with theprojection 52 disposed on the cover 40 and the receiver 56 disposed onthe base 30.

In FIGS. 1 and 2 the cover 40 includes an inner wall 42 that defines acavity. Alternatively, the cover 40 may have planar configuration suchthat the cover does not define a cavity. Where the cover does define acavity, such as in FIGS. 1 and 2, the inner wall 42 defining that cavitymay be dimensioned to contain a portion of the fuel component 20. Thecover 40 shown in FIGS. 1 and 2 is further configured to support thefuel component 20 such that the fuel component 20 is constrained frommotion relative to an axis that is perpendicular the longitudinal axis54. If the fuel component 20 is configured with a flange 24, the cover40 may engage the flange 24 to achieve that restraint. Where the cover40 engages the flange 24, the flange 24 may further engage the base.Such engagement with the base 40 may be with the platform 37 c. Thecover 40, preferably, has a tab 44 which engages the fuel component 20.As illustrated in FIGS. 1 and 2, that tab 44 may be radially disposedabout the longitudinal axis 54. The tab 44 may furthermore, support thefuel component 20, by engaging the fuel component 20 at a flange 24disposed on the fuel component 20 such that the flange is constrainedbetween the platform 37 c and the tab 44. In other embodiments, the capmay support the fuel component by forcing contact between anotherportion of the fuel component and another portion of the base to effectthe same constraint. For example, where the base is provided without arim, or the fuel component is provided without a flange, the cap maycontact another surface of the fuel component thereby applying pressureto seat the fuel component in the base.

The cover 40 may further define an annulus 46 between the tab and thesecurement. The annulus 46 may be radially disposed about thelongitudinal axis 54 as illustrated in FIGS. 1 and 2. When the flange 24is dimensioned to extend partially along the platform 37 c, as isillustrated in FIGS. 1 and 2, and the tab is engaging the platform,there will be defined a second annulus 46 a which will be incommunication with annulus 46.

The preferred embodiments described above allow for a method forencapsulating a fuel component 20 within a fuel supply. The methodincludes defining a passage 32 within a base 30 of an assembly, andseating the fuel component 20 within the passage. The method is furtheraccomplished by providing a cover 40 that is contiguous with the base30. The method also accomplished by welding the cover to the base toform a hermetic seal.

FIGS. 1 and 2 illustrate preferred embodiments that allow for themethod. In these embodiments, the fuel component defines at least oneaperture. The fuel component 20 is positioned between the cover 40 andthe base 30 such that the aperture(s) are aligned with the passage 32and such that the cover 40 and the base 30 support the fuel component 20thus restraining the fuel component 20 from movement relative to thecover and the base. The cover is then welded to the base thereby forminga contiguous member which seals the assembly against leakage of fluidfrom the assembly, i.e. forms a fluid tight seal.

The preferred embodiment also allows for a novel method of regulating afuel supply. The method can be accomplished by encapsulating a fuelcomponent 20 within a passage 32 defined by a continuous wall of ahousing, and controlling the pressure of fuel within the passage withthe fuel component. This method can be accomplished with the embodimentsalso illustrated in FIGS. 1 and 2. In these preferred embodiments, thefuel component 20 is a fuel damper or pressure regulator. The contiguouswall 37 is formed by joining the cover 40 with the base 30. There isdefined within this joined cover 40 and base 30 members a passage 32which is capable of conveying fuel through the joined cover 40 and base30. The fuel component 20 is encapsulated within this passage 32 suchthat the fuel within the passage interacts with the fuel component 20.The pressure fuel component 20 thereby controls the fuel pressure withinthe passage 32. There may be embodiments of this method where the fuelwithin the passage is controlled by channeling the fuel through the fuelcomponent 20. In that case, fuel is channeled into at least one aperture22 of the fuel component 20. The fuel that enters the aperture 22 actsagainst a diaphragm so that the diaphragm flexes to control the fuelwithin the passage 32. In FIG. 2, the fuel is channel into at least oneaperture 22′ or 22. The fuel passes through the fuel component 20 andexits the other of the at least one apertures 22′ or 22. In FIG. 1, thefuel is channelled into and exists the at least one aperture 22.

The encapsulation of the fuel component within the passage may beachieved by providing a securement 50. As illustrated in FIGS. 1 and 2,that securement may comprise a base that is contiguous with a cover. Inthe embodiments shown, the securement is achieved by joining aprojection 52 of the base 30 and a receiver 56 of the cover 40.Alternatively the securement could be rearranged so that a projection isprovided on the cover and the receiver is provided on the base.

As illustrated in FIGS. 1 and 2, the forming of the base 30 could definethe passage 32 of the method. In that embodiment, the cover 40 may beformed to interlock with the base to form a cavity between which wouldcommunicate with the passage 32. The fuel component is seated within thecavity 32 and the cover 40 is sealed to the base 30. In the embodimentsshown, the fuel component 20 is seated between the cover 40 and the base30 such that the fuel component 20 is restrained from movement relativeto the base 30 and the cover 40. In this embodiment, the cover is sealedto the base with a weldment 58.

While the present invention has been disclosed with reference to certainembodiments, numerous modifications, alterations and changes to thedescribed embodiments are possible without departing from the sphere andscope of the present invention, as defined in the appended claims.Accordingly, it is intended that the present invention not be limited tothe described embodiments, but that it has the full scope defined by thelanguage of the following claims, and equivalents thereof.

What is claimed is:
 1. A method of encapsulating a fuel component within a fuel supply comprising: defining a passage within a base of an assembly, the base having a first surface extending along a longitudinal axis; seating the fuel component within the passage; providing a cover having a second surface contiguous with the first surface of the base; and welding the second surface of the cover to the first surface of the base to form a hermetic seal without an intermediate sealing member interposed therebetween.
 2. The method of claim 1, wherein the providing a cover comprises defining a cavity with an inner wall of the cover.
 3. The method of claim 1, wherein the seating further comprises supporting the fuel component with the cover and the base.
 4. The method of claim 3, wherein the supporting further comprises: engaging a rim of the fuel component with a lip of the base; engaging a tab of the cover with the rim; and engaging a housing of the fuel component with an inner surface of the base.
 5. The method of claim 1, wherein the seating further comprises: defining at least one aperture of the fuel component; exposing the at least one aperture of the fuel component to the passage.
 6. The method of claim 1, wherein the seating further comprises: defining a plurality of apertures of the fuel component; defining a chamber of the base that is in communication with the passage; exposing at least one aperture of the fuel component to the passage; exposing at least one other aperture of the fuel component to the chamber.
 7. The method of claim 1, wherein the welding comprises engaging a projection extending along the longitudinal axis of either the cover or the base to a receiver of the other of the cover or the base.
 8. A method of regulating a fuel supply comprising: encapsulating a fuel component within a passage defined by a continuous wall of a housing, the encapsulating including providing a securement formed between a base having a first surface extending along a longitudinal axis contiguous with a second surface of a cover so that the first and second surfaces form a hermetic seal without an intermediate sealing member interposed therebetween; and controlling the pressure of fuel within the passage with the fuel component.
 9. The method of claim 8, wherein the encapsulating further comprises: forming a base to define a passage; forming a cover that is adapted to interlock with the base there being a cavity formed between the cover and the base the cavity being in communication with the passage; seating a fuel component within the cavity; and sealing the cover to the base.
 10. The method of claim 9, wherein the seating comprises defining at least one aperture of the fuel component; exposing the at least one aperture of the fuel component to the passage.
 11. The method of claim 9, wherein the seating further comprises: defining a plurality of apertures of the fuel component; exposing at least one aperture of the fuel component to the passage; exposing at least one other aperture of the fuel component to the chamber.
 12. The method of claim 9, wherein the seating further comprises supporting the fuel component with the cover and the base.
 13. The method of claim 12, wherein the supporting further comprises: engaging a rim of the fuel component with a lip of the base; engaging a tab of the cover with the rim; and engaging a housing of the fuel component with a surface of the passage.
 14. The method of claim 9, wherein the sealing further comprises positioning a rubber seal between the cover and the base.
 15. The method of claim 9, wherein the sealing further comprises welding the cover to the base.
 16. The method of claim 9, wherein the controlling comprises channeling fuel in the passage through the fuel component.
 17. The method of claim 1, wherein the welding comprises forming a plastic weldment between the cover and the base by one of spin, ultrasonic or solvent type plastic weldment.
 18. The method of claim 17, wherein the seating comprises locating a fuel component selected from a group consisting of a fuel damper and fuel pressure regulator.
 19. The method of claim 9, wherein the sealing comprises forming a plastic weldment between the cover and the base by one of spin, ultrasonic or solvent type plastic weldment.
 20. The method of claim 19, wherein the encapsulating comprises locating a fuel damper to a fixed position within the fuel component assembly, the fuel damper having an aperture in fluid communication with the passage disposed in the body.
 21. The method of claim 20, wherein the locating comprises clamping the fuel damper to the fixed position with a tab of the cover and a platform of the base.
 22. The method of claim 21, wherein the forming comprises providing a plastic body and cover. 